Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 12

12. Use protective gloves (57788093) to remove bearing cone from the heater and
immediately slide bearing cone over the spindle until it rests on the bearing cone
shoulder of the spindle. Allow time for the bearing cone to cool and shrink-fit onto
the spindle. Once cooled, apply a coat of grease (item 119, 57818221) onto the
bearing cone.

STEP 13

13. Ensure inside surface of the housing is free of dirt, metal shavings and other
contaminants by blowing shop air pressure into the housing.

Assembly/Rebuild Page 11 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 14

14. Install o-ring plugs (item 125, 95323465), pipe dope with plugs (item 18, 95033585)
and magnetic drain plug (item 107, 50137256).

STEP 15

15. Install pipe sealant plug (item 67, 95249587). This is the port utilized for the
magnetic sending unit with the rotary head option.

STEP 16

16. Install the cup of bearing (item 4, 95434551) evenly into the lower housing (item 8,
57395444). Using a bronze drift (57788101), made from 1 square key stock and a
rawhide hammer or a rubber mallet to tap the cup 90 degrees opposite side to evenly
and fully seat the cup in the housing.

Assembly/Rebuild Page 12 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 17

17. Use special tool tee-rod-hook (57788119) to pull the chain through the spindle with
bearing cone attached.

STEP 18

18. Attach ring-lock tool (57788705) to chain hook for lifting the spindle.

STEP 19

19. Insert spindle with bearing (items 1 and 4) into lower bearing race.

Assembly/Rebuild Page 13 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 20

20. Clean surface of lower seal housing (item2, 57578023), then install the first lower
seal (item 3, 52146784) to keep oil in the housing and dirt out. Refer to oil seal design
and selection for proper installation and function.

STEP 21

21. Use small steel hammer and bronze square head key stock (57788713), evenly seat
the seal by tapping 90 degrees opposite sides. Then repeat for the second seal.

STEP 22

22. After fully seating the seal, use grease (item 119, 57818221) for lubricating both
seals.

Assembly/Rebuild Page 14 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 23

23. Use grease (item 119) to lubricate the spindle area prior to installing the lower seal.

STEP 24
24. Inject silicone (item 120, 50700731) onto the circumference surface of the lower
housing to form a gasket prior to inserting the lower seal housing (57578023) with
enclosed seals over the spindle. Care should be taken not to damage or distort the
seals as they slip onto the spindle.

STEP 25

25. Align and insert screws and washers (items 5 & 6, 95934551 & 95934733) and
tighten with socket-air ratchet.

Assembly/Rebuild Page 15 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 26
26. Remove both eyebolts (57788069) from the rotary head stand, do not remove the
upper half of the pillow block and BE CAREFUL, STAND AWAY when rotating
the rotary head housing with top pointing upward. Re-insert both eyebolts into the
stand.

STEP 27
27. Use the jack attached to the stand and the round plate (57788721) underneath the
spindle so that the cup and cone of the lower bearing are pushed tightly together. The
spindle must be supported tightly to ensure proper placement of the output gear.
Remove the upper half of the pillow blocks during this process to observe shaft lift,
which indicates the lower bearing cup, is fully seated, causing the rotary head
assembly to lift.

STEP 28

28. Insert spacer (item 174, 57546319) over spindle.

Assembly/Rebuild Page 16 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

SHRINK FIT OUTPUT GEAR

STEP 29

29. Insert the custom key (item 11, 57546327) into the keyway in the spindle. Ensure the
corners and edges of the key are clean, smooth and properly dressed to accept the
output gear. The fit to the gear should be snug, but not interference fit. The key
should be tightly fit within the groove, and should be fully seated against the bottom
depth of the keyway, with contact surface to spacer (item 174). Insert the key with the
threaded, jacking hole to the top as shown.

STEP 30

30. Insert 2 special threaded eyebolts and shackle (57788739 & 57788861) to lift the
output gear (item 10, 57546301).

Assembly/Rebuild Page 17 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 31

31. Measure the hub inside diameter on the output gear (item 10) including key height.
Maximum diameter of the hub and keyway must not exceed 5.376. This will ensure
that the output gear will fit over the key during installation.

STEP 32

32. Insert the output gear onto the induction heater or into an oil bath and heat to 430F.
Ensure the gear is thoroughly heated. The fit to the spindle is a shrink fit up to 0.004.
Binding problems may arise if the gear is not sufficiently heated.

STEP 33

33. With insulated gloves (57788093), remove the output gear from the induction heater
and position the gear with the high-pressure grease hole to the top.

Assembly/Rebuild Page 18 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 34

34. With the spindle supported and lower bearing properly seated in the bearing race,
align the keyway, install the heated gear onto the spindle. The keyway should be flush
to the key as shown. Care should be taken during gear installation not to damage the
threads on the spindle.

STEP 35

35. Notice the position of the high-pressure grease hole to the top. After installation,
allow the gear and spindle to cool for at least 1.5 hours to properly shrink fit to the
shaft.

STEP 36

36. Install the 2nd spacer (item 174, 57546319) on top of the output gear.

Assembly/Rebuild Page 19 57788853

Atlas Copco Drilling Solutions DM30/45/L/ T4 Spur Rotary Head

STEP 37

37. Temporarily, install the retaining collar (item 176, 57546335) with a feeler gauge.
Remove the retaining collar and spacer. Install shims (item 175, 57546384) in equal
thickness to the gap measured. Reinstall the spacer and retaining collar.

STEP 38

38. Secure the retaining collar with cap screws (item 178, 95935235), flat washer (item
179, 95922225) and lock nut (item 180, 95923371). There should be no gap
remaining between the gear and the retaining collar. Peen the threads after inserting
the lock nut.

STEP 39

39. Installation for locknuts are opposite and the air gun is used to clean the housing of
metal shavings, dirt and other contaminates.

Assembly/Rebuild Page 20 57788853